Coating applicator kits



NOV- 2, 1965 R. v. MATHlsoN 3,215,263

COATING APPLICATOR KITS Original Filed May 23, 1963 2 Sheets-Sheet 1 INVENTOR:

ROBERT V. MATHISON ATT lYS R. V. MATHISON GOATING APPLICATOR KITS Nov.` 2, 1965 original Filed May 25,' 1965 2 Sheets-Sheet 2 FIGII FIG. I2

INVENTOR: ROBERT MATH I SON United States Patent O s Claims. (Cl. 20s- 47) This application is a divisional application of my copending application Serial No. 282,663, led May 23, 1963.

The invention claimed herein pertains to kits containing components adapted to be assembled into a coating applicator.

There is need for a new type of paint applicator which has the same ease -of handling as a paint brush but which is not so costly and does'not require the time and effort to maintain. So unpleasant and sometimes unsafe is cleaning of paint brushes that one-use throw-away brushes have been readily accepted on the market. These throw-away brushes are very inferior to the better brushes, and consequently, they do not enable a painter to do good work while still being far from cheap, A throw-away brush is therefore not much of a value, and the only justification for their existence is the need created by the consumers disinclination to have anything more to do with a brush after a painting job has been completed.

Polyurethane foam has every basic material characteristic to recommend it as a paint applicator as it is strong, it is porous, it will pick up and retain a liquid, it is inexpensive, it is immune to the chemicals in the various types of paint, and it can be cut to any size or thickness required. Added to this is the important fact that the porosity, rigidity, and cellular structure of polyurethane foam can be varied through different formulations to provide the best results with the varied basic types of paints and finishes on the market (cold Water paints, oil based paints, varnishes, enamels, and exterior paints.) In bristle brushes, very little consideration has been given to the varying viscosity and other differences which are readily apparent when each ofl these brushes are studied individually. A polyurethane applicator can be very easily formulated to take advantage of the difference in these paints.

With polyurethane foam as the paint applicator, there is no necessity to have separate brushes of varying size and shape, as is necessary with conventional bristle brushes, as this can be controlled by the operator, as will be explained later. A special type of polyurethane foam with the most compatible characteristics of porosity and flexibility can easily be selected from foam polyurethanes that are on the market for use with paints of varying chemical composition.

Having the right type polyurethane foam applicator for the right job would be simply a matter of having available two or three different types of polyurethane foam applicators, e.g. a first type of polyurethane foam applicator for applications to interior and exterior surfaces such as wood, metal and masonry with primer, sealer, casein, latex base, and alkyl oil base paints; a second type of polyurethane foam applicator for applications to interior and exterior walls, trim, sash, etc., with an oil base paint; and -a third type of polyurethane foam applicator for applications to interior and exterior walls, trim, sash, etc., with a varnish or enamel.

The polyurethane foam can be shaped to varying thicknesses and lengths. Instead of being cut into one, two, three, or four inch widths, it preferably is sold to the customer in wider sheets, e.g., twelve or twenty-four inches wide. This enables the user to cut the sheet to the exact width brush desired `for a particular job as the same 3,215,263 Patented Nov. 2, 1965 "ice handle of the preferred applicators of the invention can hold various thicknesses and widths. Since the polyurethane foam can be cut easily by standard scissors, the user can start out with a four inch polyurethane applicator to paint the walls, and by cutting the brush after the walls have been completed, the remaining part can be reduced in size sufficiently to allow it to be used to draw sash. This flexibility in changing the size of the same applicator while in use for different applications is a definite advantage.

The sheets of foam polyurethane may be of diEerent contours, e.g., tapers, from top to bottom, and the bottom edges may have inward cuts made either at the factory or by the operator for ease of application over a rough surface. The bottom edge also may be cut in the other direction (longitudinally), or a similar sheet could be manufactured by laminating together at the top several layers of thin polyurethane foam sheets, e.g., 1/16 inch or 1A inch sheets.

In painting tests conducted with polyurethane applicators of the invention, a most significant feature is that the applicator completely eliminates brush marks as well as the overlaps which can appear when a paint roller is used.

The handle for the polyurethane applicators of the invention detachably holds the applicator. In a preferred embodiment, the handle is split, hollow handle and ferrule adapted to open and close about the base or top portion of the applicator. The ferrule portion contains means to grip tightly said base when the ferrule is closed thereabout. Preferred means for this purpose are a plurality of slanting, rearwardly directed points on the inner side of the hollow ferrule to penetrate the applicator base portion and keep the applicator base locked in the ferrule when it is closed about said base portion. A separate drip collector member having an endless inner wall dimensioned to fit tightly over the outer wall of the ferrule in closed position of the ferrule and handle may be used to lock the latter in closed position.

The'features and advantages of the generic invention herein described will be appreciated further with reference to the preferred embodiments of the invention illustrated in the drawings, wherein:

' FIG. 1 is a perspective view of an applicator of the invention;

FIGS. 2 and 3 are sections taken on section planes 2-2 and 3 3 -of FIG. l;

FIGS. 4 and 5 are, respectively, a longitudinal section of the handle and ferrule component and a side elevation of the foam polyurethane applicator of the embodiment of FIG. 1;

FIGS. 6, 8 and 9, respectively, are enlarged, top plan, side elevation and front elevation views of one of the multi-prong members in the ferrule of the embodiment, while FIG. 7 is a further enlarged view of a fragment thereof in side elevation;

FIG. 10 is a perspective view of a package of the charracter in which the handle, drip cup, and several foam polyurethane applicators may be assembled for marketing the applicators of the invention; and

FIGS. ll and 12 are, respectively, a side elevation and a perspective view of two other embodiments of the foam polyurethane applicators of the invention.

Referring to the drawings, the illustrated applicator comprises a tapered block 1 of foam polyurethane having side walls 2, 3 tapered from the base 4 to the flexible, narrow, wiper or spreader edge 5. The edge 5 may be a sharp edge or may be a narrow, slightly blunt edge (as shown).

The handle and ferrule part of the applicator is one ir 1 which at least the ferrule portion of the member can be opened and closed to remove and insert foam polyurethane applicators. In the embodiment illustrated, the handle and ferrule are molded in a single molding operation as separable, opposing half sections 7, 8. The hollow handle is composed by opposing, symmetric, transversely arched sections 9, 9 which taper longitudinally toward the ferrule sections 10, 10. The ferrule sections 10, 10 are molded integrally with bases of handle sections 9, 9 by walls extending outwardly and forwardly from said bases. The hollow ferrule is formed by front and rear walls 11, 12 molded integrally with, respectively, abuttable end wall pairs 13, 15 and 14, 16, and abuttable, curved, top walls 17, 18. The abuttable edges of handle sections 9, 9 and wall pairs 13, 15 and 14, 16 and 17, 18 may have tongues or ribs 19, 20 which will form lap joints between the handle and ferrule half section walls when they are brought together. The lower or outer edges of walls 11 and 12 may have a stepped, inward taper 21. A stippled or other rough textured surface 22 may be mold- 'ed into, or later applied to, the handle surface and the part of the ferrule surface used in some cases to grip the brush in order to improve the grip qualities thereof.

The ferrule sections 10, 10 each have a cross wall 23, 24, respectively, each cross wall having a tongue or rib 25, 26 across its edge. The tongues or ribs form a lap joint when the half sections are closed. The cross wall formed thereby, together with the front, rear and end walls of the ferrule, form a five-sided chamber in which the base 4 of applicator 1 is inserted.

In order to provide for removal and insertion of the replaceable applicator 1, the ferrule sections 10, 10' are separable. To this end, the applicator may be constructed in a manner whereby the handle portion is a one-piece handle and only the ferrule is Capable of being opened and closed. It is preferred, however, for simplicitys sake to mold the handle and the ferrule together in the form of separable sections. By connecting the ends of the yhandle sections 9, 9' by a strip of plastic 27, e.g., by molding sections 7, 8 in the same mold with the strip 27 molded integrally therewith, a hinge between said sections is formed by strip 27 which allows sections 7, 8 to open and close. The sections 7, 8 may have near the flexible hinge strip 27 mating, inwardly directed cylindrical walls 28 which form, when the sections are closed, a cylindrical passage through the handle by which the applicator can be, on a nail, cord, etc., hung on a wall or the like.

The foam polyurethane applicator is held releasably in the cavity in the base end of the ferrule by fastener members 30, each comprising a back or plate member attached by any suitable means, such as adhesive, to the inner sides of walls 10, 10 with a plurality of sloping, tapered projections positioned to slope inwardly toward cross walls 23, 24. These projections penetrate the base 4 of the polyurethane foam applicator when the ferrule and handle are closed. Their slope works against forces on the applicator 1 which would tend to pull it out of the ferrule. The tips 33 preferably are pointed or slightly blunted. The slope and length of the projections 32 preferably are such that a vertical line from the tips 33 toward base 31 intersects the base portions 34 of projections 32 in the next adjacent row.

The fasteners 30, in the illustrated case, are molded units comprising a supporting structure of a synthetic polymer having a plurality of smooth sided, substantially rigid, closely spaced projections integrally formed of said polymer on at least one side f said supporting structure and tapering from their bases to relatively sharp tips. The said projections preferably extend outwardly from said supporting structure at an angle of 30 to 80. These projections are preferably closely spaced in parallel rows in which they all extend in the same direction and the rows are close enough together so that the tips of projections in one row extend above the sides, or partially overlap, the projections in an adjacent row. In other words, if a vertical line were drawn from the tip of one projection it would intersect the side of an adjacent projection. The

projections are preferably conical or pyramidal and are spaced from one another at their bases a distance of 0.03 to 0.10 inch. They also preferably have a centerto-center spacing at their tips from 0.03 to 0.25 inch. The size of the bases of the projections is preferably at least 0.03 inch in one dimension. The vertical height of the tips of the projections from the supporting structure is preferably within the range of 0.03 to 0.150 inch. The number of projections is preferably within the range of 200 to 500 per square inch.

As a typical example, the projections can be 0.050 inch in length and slanted at an angle of 45 with the supporting structure. The bases of these projections can be 0.030 inch in diameter and taper to a tip having a diameter of 0.010 inch. The supporting structure can be 0.014 inch in thickness at places where there are no projections and the over-all thickness from the tips of the projections through the supporting structure can be 0.064 inch. There can be a projection tip every 0.050 inch or about 400 points per square inch.

As another example, the thickness of the supporting structure can be 1/32 inch. The projections can be slanted at an angle of 55. The projections are disposed in rows in two directions, the rows being /f; inch apart and the projections being 1%[6 inch apart center-to-center in each row. The vertical height from the tips of the projections to the top of the supporting structure can be 1/16 inch. Considering each projection as a cone, the base can be 1,(32 inch. The projections can overlap each other to the extent that a vertical line drawn from the tip of one projection will substantially intersect the mid-point of the base of the preceding projection. Thus, a fastener of this type containing eight projections in each row longitudinally and seven rows laterally will occupy a space of approximately 1/2 inch on each side allowing some room for margins.

The size and arrangement -of the projections will vary to some extent depending upon the intended use but in most cases it is preferable that the projections be integrally formed or molded on a supporting sheet at an angle of 45 to 60, that the adjacent projections be separated from each other center-to-center by a distance of from 0.060 to 0.150 inch', and that the Vertical height from the tips of the projections to the surface of the Asupporting sheet be from 0.060 t-o 0.11'50 inch.

The synthetic polymer from which the fastener is formed can be a homo-polymer, such as al polymer of formaldehyde (e.g., Delrin), or a polymer of tetrafluoroethylene (e. g., T efion), or polyethylene or polypropylene, or a copolymer (e.g., nylon). These polymers can also be described as synthetic resins. i

The handle and ferrule sections 7, 8 can be locked together by snap connections, U-clips, bands, or other means, if desired. It is preferred, however, to use the drip collector 36 for this purpose as well as for collecting any paint, etc., which runs off applicator 1, e.g., while painting ceilings. The inner wall 37 is a stepped, tapered Wall acting as a perimetric band about the lower portion of the ferrule. When the drip collector is slipped over the base of the ferrule, stepped wall 37 tits against the tapered, stepped portion 21 of ferrule walls 11, 12 to hold the ferrule and handle in interengaged, closed position with applicator 1 locked in the ferrule cavity by fasteners 30. The outer, peripheral wall 38 and connecting bottom wall 39 form, with inner Wall 37, the perimetric, drip collection chamber 40.

The convenience and economical advantages of the invention will be further appreciated from the article of commerce shown in FIG. 10, which illustrates a package or kit in which the articles of invention can be marketed. T-he package comprises at least one, and in the illustrated case, three tapered, foam polyurethane strips 41, 42, 43. These strips are relatively long, several times longer than the ferrule is wide. They may be cut to the appropriate length desired by the user with an ordinary scissors as a new applicator member is needed. Where the package contains a plurality of said strips, they may be the same type or may be lof different type, eg., dilferent tapers and/or foam characteristics to allow the user to select the type most suitable for his particular use at a particullar time. The package or kit may be a boX, sack, or the like, or, as in the illustrated case, a thermoplastic polymer l-m envelope or bag 44 having its 'open end closed by a band 45 or other suitable means, e.g., a heat seal, clip, etc. The handle and ferrule unit 6 and the drip collector 36, supra, are also in the package to supply the complete unit.

In FIG. 1l, there is shown a foam polyurethane applicator 46 formed by thin, superposed layers 47 of foam polyurethane. The layers are vulcanized or otherwise attached together, e.g., by staples, at the base portion 48. The remainder of the layers are unattached and can llex somewhat to provide a plurality of paint spreader edges 49 when the applicator is brushed over a surface 50.

In FIG. 12, the foam polyurethane applicator 1 is of similar structure and shape to applicator 1. It has, however, a plurality of slits 51 cut from the tapered edge toward the base 53 to provide a plurality of narrow, sideby-side strips 52. This applicator is especially useful in applying paint or other coating to uneven Surfaces.

The principal portion of the foregoing specification pertains to foam polyurethane applicators, which constitute the preferred cellular material. The invention also embraces, however, other cellular, foam polymers, e.g., foam rubber and foam synthetic rubber, having an open cell struct-ure providing some absorbency of the coating materials.

It is thought that the invention and its numerous attendant advantages will be fully understood from the foregoing description, and it is obvious that numerous changes may be made in the form, construction and arrangement of the several parts without departing from the spirit or scope of the invention, or sacrificing any of its attendant advantages, the forms herein disclosed being preferred embodiments for the purpose of illustrating the invention.

The invention is hereby claimed as follows:

1. A coating applicator kit comprising means forming a package containing a handle and ferrule member in which a foam polymer applicator body may be inserted to form a coating applicator assembly and at least one elongated foam polymer applicator body with a pair of opposite faces tapering from a base portion to a substantially sharp edge, said applicator body having a length at least several times the width of said ferrule, whereby a predetermined amount of said applicator body can be cut 'olf and mounted in said ferrule to form a coating applicator assembly of the character desired for a particular use.

2. A coating applicator kit comprising means forming a package containing a handle and ferrule member in which a foam polymer applicator body may be inserted to form a coating applicator assembly and at least one elongated foam polymer applicator body having a length at least several times the width of said ferrule and a coating applicator portion along one longitudinal edge thereof whereby a predetermined amount of said applicator body can be cut off and mounted in said ferrule to form a coating applicator assembly `of the character desired for a particular use.

3. A kit as claimed in claim 2 wherein said package contains a plurality of polyurethane applicator bodies of a length as aforedeiined, said applicator bodies having different foam qualities suited for different types of coating applications.

4. A kit as claimed in claim 2 wherein said package also contains a drip collector embodying an endless inner wall connected by a bottom wall with an endless outer Wall, said inner, bottom and outer walls forming a perimetric drip collection chamber open at one end thereof, and said inner wall being dimensioned to t snugly about the outer sides of said ferrule with the open end facing away from said handle.

5. A kit as claimed in claim 4 wherein said ferrule comprises separable sections, and said drip collector is adapted to hold said sections together when snugly tted about the outer sides of said ferrule.

References Cited by the Examiner UNITED STATES PATENTS 1,384,936 7/21 Bowman 30G-2l THERON E. CONDON, Primary Examiner. 

1. A COATING APPLICATOR KIT COMPRISING MEANS FORMING A PACKAGE CONTAINING A HANDLE AND FERRULE MEMBER IN WHICH A FOAM POLYMER APPLICATOR BODY MAY BE INSERTED TO FORM A COATING APPLICATOR ASSEMBLY AND AT LEAST ONE ELONGATED FOAM POLYMER APPLICATOR BODY WITH A PAIR OF OPPOSITE FACES TAPERING FROM A BASE PORTION TO A SUBSTANTIALLY SHARP EDGE, SAID APPLICATOR BODY HAVING A LENGTH AT LEAST SEVERAL TIMES THE WIDTH OF SAID FERRULE, WHEREBY 